Carpet constructions, systems, and methods

ABSTRACT

A textile substrate such as patterned carpet for coordinating with other flooring is provided. The substrate includes a multi-colored pattern produced by a process for coloring substrates, using the application of liquid colorants, in which the assignment of color is done on a pixel-by-pixel basis, and corresponding products. Relatively large areas of a substrate may be given the appearance of being uniformly colored by successively replicating or tiling a group of individually colored pixels comprising a repeating unit (i.e., a superpixel) across the substrate surface. The repeating unit is constructed in such a way that if a colorant application error develops, causing one or more pixels within the repeating unit to be colored incorrectly or incompletely, the overall arrangement of the pixels within the repeating unit will render such error less visually apparent when viewed on the substrate. A display rug having a plurality of areas of different patterns, colors or shades is provided. Also, a display rug and a display cover is provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 10/138,837, filed on May 3, 2002, hereby incorporated byreference herein.

The present invention relates to novel textile substrates,constructions, samples, rugs, colors, designs, and/or patterns, as wellas systems, methods, processes, and/or techniques utilizing suchconstructions, samples, rugs, colors, designs, and/or patterns formarketing, merchandizing, and/or selling such products, and/or methodsof producing such products. More particularly, the textile substrates orconstructions are preferably floor covering or surface covering productssuch as carpet or carpet tiles, especially printed or dyed carpet.

At least certain preferred embodiments of the novel developmentsdescribed herein also relate to a process for coloring substrates, usingthe application of liquid colorants, in which the assignment of color isdone on a pixel-by-pixel basis. Specifically, the following describes aprocess, and the resulting product, whereby relatively large areas of asubstrate may be given the appearance of being uniformly colored bysuccessively replicating or tiling a group of individually coloredpixels comprising a repeating unit (i.e., a superpixel) across thesubstrate surface. The repeating unit is constructed in such a way thatif a colorant application error develops, causing one or more pixelswithin the repeating unit to be colored incorrectly or incompletely, theoverall arrangement of the pixels within the repeating unit will rendersuch error less visually apparent when viewed on the substrate.

Many techniques have been developed for patterning or coloringsubstrates, notably absorbent substrates, and particularly textilesubstrates. With the development of the electronic computer, suchtechniques have included the use of individually addressable dyeapplicators, under computer control, that are capable of dispensing apre-determined, and in some cases, variable, quantity of a dye or liquidcolorant to a specifically identified area or pixel on a substratesurface. Such techniques have been disclosed in, for example,commonly-assigned U.S. Pat. Nos. 4,116,626, 5,136,520, 5,142,481, and5,208,592, the teachings of which are hereby incorporated by reference.

In the devices and techniques described in the above-referenced U.S.patents, the pattern is defined in terms of pixels, and individualcolorants, or combinations of colorants, are assigned to each pixel inorder to impart the desired color to that corresponding pixel orpixel-sized area on the substrate. The application of such colorants tospecific pixels is achieved through the use of hundreds of individualdye applicators, mounted along the length of color bars that arepositioned across the path of the moving substrate to be patterned. Eachapplicator in a given color bar is supplied with colorant from the samecolorant reservoir, with different arrays being supplied from differentreservoirs, typically containing different colorants. By generatingapplicator actuation instructions that accommodate the position of theapplicator along the length of the color bar and the position of thecolor bar relative to the position of the target pixel on the movingsubstrate, any available colorant from any color bar may be applied toany pixel within the pattern area on the substrate, as may be requiredby the specific pattern being reproduced.

It is contemplated that other arrangements or techniques forsystematically applying various colorants to a substrate surface inaccordance with pattern data, such as, for example, having one or moresets of colorant applicators that are moved or indexed across the faceof a relatively stationary or intermittently indexed substrate, may alsoemploy the teachings herein.

Regardless of the nature or configuration of the patterning device, acommon problem with the use of such devices involves the occasionalmalfunction of one or more of the colorant applicators, as when suchapplicators become clogged, blocked, mis-aligned, or otherwise becomeincapable of reliably and accurately dispensing to each assigned pixelthe required quantity of the assigned colorant to that pixel. If themalfunction is intermittent, such as an applicator that occasionallydispenses the incorrect quantity of colorant, the resulting patterningirregularity may be relatively unobtrusive, depending, of course, uponthe nature of the pattern being reproduced, the nature of the substratebeing patterned, and other factors. If the malfunction is persistent,such as an applicator that has become blocked, mis-aligned, or hasceased to function altogether, the resulting patterning irregularity maybe so obtrusive as to cause visually objectionable streaks, bands, orthe like that tend to extend in the direction of primary relative motionbetween the colorant applicator(s) and the substrate, hereinafterreferred to as the “machine direction” (e.g., as indicated by the arrowin FIGS. 1 and 2).

The result of such malfunctions manifests as linear patterning anomaliesknown as “streaks” or “bands” and may be somewhat visually analogous tothe striations associated with old or worn film or videotape images.Areas of the substrate in which the pattern requires a relativelyuniform solid color or shade to be reproduced on the substrate aregenerally the least tolerant of either type of malfunction—suchmalfunctions result in solid color areas that are non-uniform, eitherdue to the formation of the streaks and bands referred to above, or dueto otherwise unintended and visually objectionable patternirregularities. Accordingly, the uniform appearance of such areaspatterned by such patterning devices as described above has beenparticularly dependent upon the absence of colorant applicatormalfunctions.

By use of the teachings herein, substrate pattern areas may be generatedthat effectively emulate uniformly colored pattern areas, but that havedramatically increased tolerance for individual colorant applicatormalfunctions that might otherwise render such pattern areas distinctlynon-uniform and visually objectionable. In accordance with oneembodiment of the teachings herein, areas of the substrate that areintended to carry a solid color or shade instead may be patterned withan arrangement of different colored pixels, selected to replicate therequired color on the substrate, that collectively comprise a repeatingunit or superpixel.

The distribution of such colored pixels within such superpixel arecarefully constructed to avoid or minimize the formation of visuallyobtrusive clumps or islands of color within the superpixel, as well asthe unintended alignment of such pixels either within a given superpixelor across several superpixels, particularly in the machine direction. Insingle color areas, the former condition tends to promote a speckled orheathered appearance, which may or may not be desirable, while thelatter condition tends to generate visually apparent twill lines undersome conditions. When such repeating unit or superpixel is tiled orotherwise replicated across the substrate surface and observed at adistance, this patterned area—although generally comprised of a densearrangement of chromatically compatible, but not identically colored,pixels—is capable of serving as an effective visual surrogate for auniformly colored solid shade area on the substrate.

Advantageously, the resulting pattern area, which may, in some cases,result in a somewhat “heathered” appearance, effectively disguisespatterning irregularities due to the misapplication of colorant byindividual, improperly functioning colorant applicators in individualpixel areas, particularly in cases in which colorant applicatormalfunctions are persistent and result in a systematic patterningirregularity that is replicated throughout the pattern area. It has alsobeen found that, through use of such “fault-tolerant” superpixels, theresulting pattern area tends to allow contours in the surface of thesubstrate, as, for example, would be found in a multi-level carpetsubstrate, to maintain a desired degree of visual prominence, which thegeneration of bands, streaks, and the like tends to obscure.

In another embodiment of the teachings herein, the pixels comprising thesuperpixel may be identically colored, but may be colored in a mannerthat involves the use of multiple (and technically redundant) colorantapplicators to provide an applicator-to-pixel relationship that candisguise individual improperly functioning colorant applicators, as willbe discussed in further detail below.

For purposes herein, the following terms shall have the indicatedmeanings, unless the context or explicit language otherwise dictates.

The term “pixel” shall refer to the smallest area or location in apattern or on a substrate that can be individually assignable oraddressable with a given color.

The term “pattern” and its derivative terms shall mean assigning orimparting one or more colors to a substrate surface, and shall referboth to the assignment of colors to specific pixels and to thecorresponding dispensing of liquid colorants on the substrate surface.When used in the sense of a pattern on a substrate surface, the termshall refer to the arrangement of textile fibers that have been dyed bythe application, on a pixel-by-pixel basis, of a liquid colorant to thesurface of the substrate. While a pattern typically involves differentcolors, arranged in pre-determined configurations or designs, placed orto be placed in various areas of the substrate surface, it may alsorefer to the assignment or generation of a single color in all areas ofthe substrate surface, i.e., a “solid color” pattern. In either case,the color(s) may be generated on the substrate surface through thepixel-by-pixel application of a single liquid colorant (e.g., if thedesired color can be reproduced using a single process color), or theapplication of several different liquid colorants to form an in situblend on the substrate surface.

The term “heather” and its derivative terms shall mean small scalechromatic non-uniformities within a patterned area on a substrate,somewhat analogous to grain in a photograph or the halftone structure ina printed halftone image. Substrates with significant heather appearspeckled or stippled when viewed at close range, although may appear toexhibit a solid color when viewed at a greater viewing distance. In somecases, the generation of heather is desirable, as it provides for thepresentation of a variety of different colors, or different shades ofthe same color, in a way that is visually apparent, but subtle andunobtrusive.

The term “adjacent” and its derivative terms shall be used to meancontiguous, including along a diagonal, i.e., having a shared, commonboundary element, including a common side or a common corner.

The term “side-wise adjacent” shall refer to a particular kind ofadjacent or contiguous orientation in which the common boundary elementconsists of at least one common side (i.e., the sharing only of a commoncorner falls within the definition of adjacent, but does not fall withinthe definition of side-wise adjacent).

The term “dithering” shall refer to a computer-generated reconstructionof an image, using only pixels having colors found in a pre-defined“dither palette”. Dithering software generates, in pixel-wise fashion,an image in which each pixel is assigned a color from the dither palettethat, when the image is viewed from a distance, best approximates thetarget color at that location within the pattern.

The term “Multi-pixel Offset Unit” or “M.O.U.” shall be used to describethe smallest group of pixels that collectively represent the desiredcolor. In one embodiment of the teachings herein, an M.O.U. can bethought of as the major component or building block of a superpixel thatimparts the correct color (but not necessarily the correct internalplacement of pixels) to that superpixel. In that embodiment, severalM.O.U.s are arranged so that pixels having the same color are assignedto different columns (i.e., a series of contiguous pixels extending inthe machine direction) on the substrate. A specific arrangement ofadjacent M.O.U.s can form a superpixel that, when tiled across an areaof the substrate, will form the desired color while minimizing thealignment, in the machine direction, of pixels having the same color,thereby making relatively inconspicuous any patterning irregularities(e.g., the formation of streaks and bands) due to the malfunction of anyspecific colorant applicator.

The term “superpixel” refers to a pre-defined arrangement of pixels,each carrying a pre-determined color (generated by a single processcolorant, or by an in situ blend of two or more process colorantsapplied to the same or adjacent pixels), to be tiled or otherwisereplicated across an area on a substrate surface in order to impart aspecified color or pattern effect to that substrate surface area. In oneembodiment of the teachings herein, a superpixel may be formed by anarrangement of several M.O.U.s or, in another embodiment of theteachings herein, may simply be an arrangement of individual pixels.When used in the context of patterning, the terms “superpixel” and“repeating unit” may be used interchangeably. Superpixels can containseveral or dozens of individual pixels.

The term “machine direction” shall refer to the relative direction ofmovement of the colorant applicators as they are dispensing colorantonto the substrate. It is presumed that the substrate to be patterned iseither in the form of a continuous web, e.g., a broadloom floorcovering, or is in the form of a series of discrete substrate units,e.g., individual carpet tiles or area rugs, moving along a path leadingthrough the patterning device of choice. Where the applicators aremaintained in a fixed position (e.g., on non-moving color bars), themachine direction corresponds to the direction of motion of thesubstrate through the patterning device. Where the applicators aremounted on a moving platform, e.g., one that traverses across the pathof the substrate, the machine direction may be transverse to thedirection of motion of the substrate.

The terms “column” and “row” shall refer, respectively, to axes withinpixel arrays extending in the machine direction (column) and transverseto the machine direction (row), respectively. With respect to thepatterning device of FIGS. 1 and 2, a column of pixels within an M.O.U.or superpixel extends along the length of the conveyor (and extendsvertically in the Figures representing individual pixels).

The term “tile” and its derivative terms shall have the conventionalmathematical definition, i.e., to position similarly-shaped elements(such as superpixels or other pattern repeat units) having complementaryboundaries in adjacent relationship with one another on a surface, so asto cause said complementary boundaries to become common boundariesbetween adjacent elements, and thereby form a continuous, uninterruptedexpanse of said elements over the surface on which said elements arepositioned, similar to a jig saw puzzle with identically-shaped pieces.

The term “process colorant” and its derivative terms shall refer to thecolorant applied to the substrate by the colorant applicator system. Theterm “process color” and its derivative terms shall refer to theintrinsic color of the process colorant, prior to any mixing with othercolorants on the substrate surface. Process colors, therefore, arecolors obtainable without the need for mixing or blending differentcolorants on the substrate.

The term “twill line” shall refer to the relative position ofsimilarly-colored pixels or pattern elements within a pattern repeatunit that, when the repeat unit is tiled across the substrate, producesan unintended alignment of such pixels or pattern elements that appearsas a visually apparent line or band extending, commonly (but notnecessarily) in a diagonal direction, over multiple superpixels orpattern repeats.

The term “in situ blend” and its derivative terms shall refer to theseparate application of two or more colorants to the same or adjacentpixels on a substrate, with at least some mixing or blending of thecolorants taking place following such application.

The term “target color” shall refer to the color specified in thepattern that is to be reproduced or emulated on the substrate usingprocess colorants, perhaps through the use of in situ blendingtechniques, dithering techniques, or a combination of those techniques.

The term “fill color” shall refer either to a solid color or shade(i.e., a color or shade that is visually uniform and homogeneous) thatis formed by a collection of pixels in which all individual pixels havebeen assigned the same color, or to a color that is formed by acollection of pixels in which at least two pixels within the collectionhave been assigned different colors in a manner that minimizes anyvisually discernable pattern to the positioning of differently coloredpixels. In this latter case, the resulting color may exhibit a heatheror stipple effect when viewed at close range, but may give theappearance of a solid color when viewed at a distance.

The term “fill area” shall refer to areas within a pattern to which areassigned fill colors.

The term “periodic” and its derivative terms shall refer to thesystematic, predictable appearance of an irregularity, a specificallycolored pixel, or other identifiable pattern component on the substrate.The term “non-periodic” and its derivative terms shall refer to therandom or quasi-random appearance of such pattern components on thesubstrate.

The term “pattern artifact” and its derivative terms shall refer to theintroduction of an unintended design element in situations wherein arepeating unit is replicated within an area of the substrate. A patternartifact arises when certain components within that repeating unitbecome geometrically aligned with similar components in adjacentrepeating units in a way that introduces an unintended design element,such as a twill line, which typically spans many repeating units and isrelatively unobtrusive or non-existent when viewed only within thesingle repeating unit.

The term “pattern irregularity” and its derivative terms shall refer todeviations between the pre-determined pattern and the pattern asreproduced on the substrate. A pattern irregularity, if periodic, canform a pattern artifact.

The term “textile floor covering” shall refer to any absorbent textilesubstrate (e.g., one that may be described as a non-woven, woven,tufted, bonded, knitted, flocked, or needlepunched textile substrate)that is adapted (perhaps with the addition of an appropriate textile ornon-textile backing material) or suitable for placement on a floor orother walking surface. Specifically included as non-limiting examplesare carpets, carpet tiles, broadloom, rugs, area rugs, runners, andmats, any of which may be variously comprised of natural and/orsynthetic fibers, such as polyamide fibers, wool fibers, or combinationsthereof. Non-limiting examples of carpet tiles are described in moredetail in commonly-assigned U.S. Pat. Nos. 4,522,857 and 6,203,881, eachhereby incorporated by reference herein.

BRIEF DESCRIPTION OF THE DRAWINGS

“The patent or application file contains at least one drawing executedin color. Copies of this patent or patent application with colordrawings(s) will be provided by the Patent Office upon request andpayment of necessary fee.”

FIG. 1 schematically depicts an exemplary patterning device in which aplurality of individually controllable colorant applicators, arrangedalong the length of a series of color bars, are deployed across the pathof a substrate web to be patterned.

FIG. 2 schematically depicts a plan view of the device of FIG. 1,showing patterned areas of the substrate, intended to be uniformlycolored, that carry several patterning artifacts caused by individualcolorant applicator malfunctions.

FIGS. 3A through 3D depict patterned areas of a substrate at anindividual pixel scale. FIG. 3A depicts a fill area of an originalpattern, showing the confinement of light and dark pixels to variouscolumns within the pattern. FIG. 3B depicts the results of applying theteachings herein to construct an Multi-pixel Offset Unit (“M.O.U.”) tobe used in forming an appropriate superpixel in which each column of thepattern contains all four of the individual pixel colors, in accordancewith one embodiment of the teachings herein. FIG. 3C depicts theresulting superpixel, suitable for tiling within a fill area of thepattern. FIG. 3D depicts the superpixel as tiled within a fill area.

FIG. 4 depicts a four-by-four pixel array (i.e., a superpixel) thatindicates the placement of different colorants within the array inaccordance with the teachings herein.

FIG. 5 depicts a six-by-six pixel array (i.e., a superpixel) thatindicates the placement of different colorants within the array inaccordance with the teachings herein.

FIG. 6A depicts an eight-by-eight pixel array (i.e., a superpixel) thatindicates the placement of different colorants within the array inaccordance with the teachings herein.

FIG. 6B depicts an alternative eight-by-eight pixel array (i.e., asuperpixel) that indicates the placement of different colorants withinthe array in accordance with the teachings herein.

FIG. 7 depicts a ten-by-ten pixel array (i.e., a superpixel) thatindicates the placement of different colorants within the array inaccordance with the teachings herein.

FIG. 8 depicts a twelve-by-twelve pixel array (i.e., a superpixel) thatindicates the placement of different colorants within the array inaccordance with the teachings herein.

FIG. 9 depicts a textile substrate such as a carpet, having asubstantially flat surface which has been patterned in accordance withthe teachings herein.

FIG. 10 depicts a textile substrate, such as a carpet or carpet tile,having a contoured, textured or uneven surface which has been patternedin accordance with the teachings herein.

FIGS. 11A-19 schematically depict respective top plan views of textilefloor covering or textile substrates or constructions such as broadloomcarpet, rugs, carpet tiles, runners, mats, or the like such as displayrugs having respective selected areas of different colors, shades,patterns, and/or the like in accordance with exemplary embodiments ofthe present invention.

FIGS. 11A and 11B each depict a textile substrate having selected areasor blocks of different colors or shades of color (solids or heathers).

FIGS. 12A and 12B each depict a textile substrate having selected areasor blocks of different patterns, designs and/or colors.

In each of FIGS. 11A and 12A, the areas of different colors, shades,patterns, designs, textures, and/or the like are separated by a borderor frame such as a black or white border.

FIG. 13 depicts a textile substrate having selected areas or blocks ofdifferent shades of red (solids or heathers).

FIG. 14 depicts a textile substrate with selected areas or blocks of thesame pattern with different background colors or shades (solids orheathers).

FIG. 15 depicts a textile substrate with selected areas or blocks ofdifferent colors or shades and patterns.

FIG. 16 depicts a textile substrate with selected areas or blocks withdifferent background and pattern colors or shades.

FIG. 17 depicts a textile substrate with selected areas or blocks, orsections of different color or shade and bases.

FIG. 18 depicts a textile substrate with selected areas or blocks ofdifferent shades of color with corresponding color codes.

FIG. 19 depicts a textile substrate with selected areas or blocks ofdifferent colors and/or patterns with corresponding pattern and/or colorcodes.

FIG. 20 depicts a photographic representation of a textile substratesuch as a display carpet or rug having rectangular areas or blocks ofselected colors (heathers) in a rectangular array. The display rug islocated atop a hallway of patterned carpet tile.

FIGS. 21-27 depict photographic representations of respectivearrangements of products adjacent heather pattern or color textilesubstrate such as carpet showing the coordinating effect in accordancewith exemplary embodiments of the present invention.

FIG. 21 is a photographic representation of four ceramic tiles placedover a heather patterned textile substrate.

FIG. 22 is a photographic representation of six tiles or tile piecesplaced over the heather patterned textile substrate of FIG. 21.

FIG. 23 is a photographic representation of four different tiles or tilepieces over the heather patterned textile substrate of FIGS. 21 and 22.

FIG. 24 is a photographic representation of a piece of patterned carpetwith one edge adjacent to eight different heather patterned textilesubstrates.

FIG. 25 is a photographic representation of three different tiles ortile pieces placed over a tray filled with swatches, samples or piecesof different heather patterned textile substrates.

FIG. 26 is a photographic representation of a tile placed over a trayfilled with swatches, samples, or pieces of different heather patternedtextile substrates.

FIG. 27 is a photographic representation of two tiles placed adjacent atray filled with a plurality of different heather patterned textilesubstrate pieces or samples.

FIGS. 28-35 are black and white copies of the color FIGS. 20-27.

FIG. 36 is a front view of an exemplary display cover having respectivetransparent windows for each of the color, pattern, or shade areas of atextile substrate or construction (such as shown , for example, in anyone of FIGS. 11A-16) and frame or border elements to divide the color,pattern or shade areas, and having space for color, pattern, shade,design, base, and/or the like identifying text or numbers, bar codes,SKU number, and/or the like for each of the color, pattern or shadeareas.

FIG. 37 is a front view of an exemplary display unit including thedisplay cover of FIG. 36 over the display rug of either FIG. 11A or 11B.

FIGS. 38 and 39, like FIGS. 11A-19, schematically depict respective topplan views of textile substrates or constructions such as textile floorcovering, surface covering, wall covering, or the like.

FIG. 38 depicts a textile substrate having circular areas of differentcolors or shades which are separated from one another by, for example, abackground of white or light beige.

FIG. 39 depicts a textile substrate having elongated rectangular stripsor stripes of areas of different colors or shades.

FIG. 40 is a top view color representation of a color family display rugin accordance with one particular embodiment of the present inventionhaving 15 different, contiguous, square areas of different colors orshades.

FIG. 41 is a photographic representation of an exemplary display systemholding 10 display rugs like that of FIG. 40. FIG. 42, is a photographicrepresentation of a person kneeling over a plurality of display rugssuch as those shown in FIG. 41 and coordinating the colors of thedisplay rugs with a particular piece of pattern carpet. The piece ofpattern carpet includes a number of different colors or shades in afloral design. The person can visually match or coordinate a particularcolor or shade area of a display rug with one or more of the colors orshades in the floral pattern.

FIGS. 43-45 are respective black and white copies of FIGS. 40-42.

DESCRIPTION OF PREFERRED EMBODIMENTS

The superpixel constructions of at least certain preferred embodimentsdescribed herein can be used in conjunction with a variety of patterningdevices and substrates, so long as the patterning device is capable ofapplying colorants to the substrate on a pixel-by-pixel basis inaccordance with pre-defined patterning data. FIG. 1 shows an exemplaryjet dyeing apparatus 10, such as a Millitron® textile patterning machinedeveloped by Milliken & Company of Spartanburg, S.C., comprised of a setof eight individual color bars 15, with each color bar capable ofdispensing dye of a given color, positioned in fixed relationship withinframe 20. A greater or fewer number of color bars may be used, dependingupon the desired complexity of the apparatus, the need for a wide rangeof colors, and other factors.

Each color bar 15 is comprised of a plurality of individuallycontrollable dye applicators arranged in spaced alignment along thelength of the color bar and supplied with the colorant assigned to thatcolor bar. The number of applicators per unit length of the color barmay be, for example, ten to the inch, twenty to the inch, or some othernumber. Each color bar extends across the full width of substrate 25. Asdepicted, unpatterned substrate 25, such as a textile fabric, may besupplied from roll 30 and is transported through frame 20 and under eachcolor bar 15 by conveyor 40, which is driven by a motor indicatedgenerally at 44. After being transported under color bars 15 in a mannerthat provides for the accurate pixel-wise placement of colorant inprecisely-defined areas of the substrate, now-patterned substrate 25Amay be passed through other dyeing-related coloring steps such asdrying, fixing, etc. With appropriate modification of the transportmechanism, the substrate to be patterned may also be in the form ofdiscrete units (e.g., individual carpet tiles, mats, or the like).

FIG. 2 is a schematic plan view of the patterning device of FIG. 1.Included in this view are block representations of computer system 50associated with electronic control system 55, electronic registrationsystem 60, and rotary pulse generator or similar transducer 65. Thecollective operation of these systems results in the generation ofindividual “on/off” actuation commands that result in the accuratepixel-wise application, on the surface of moving substrate 25, of thecolorants necessary to reproduce the desired pattern using thepattern-specified colors, as described in more detail incommonly-assigned U.S. Pat. Nos. 4,033,154, 4,545,086, 4,984,169, and5,208,592, each of which is hereby incorporated by reference herein.

In the operation of patterning devices such as that depicted in FIGS. 1and 2, occasionally one or more of the hundreds or thousands ofindividual dye applicators, each of which may comprise preciselydesigned, individually-actuatable electro-mechanical valve mechanismsand fluid passageways, may fail to deliver the appropriate volume ofliquid colorant to the specified area on substrate 25. Typically, thissituation may be due to a mis-alignment, mis-adjustment or a blockage orother malfunction of the applicator(s). If the problem is transient innature, the resulting pattern irregularity may be quite localized on thesubstrate and may not be visually obtrusive (depending upon the natureof the pattern, the selected colors, and other factors). If, however,the problem is persistent or frequently recurring, the resulting patternirregularity may manifest as a noticeable line, streak, or band thatextends for some distance in the machine direction, as shown at 84, 86,and 88 in FIG. 2. In either case, the resulting patterned substrate mustbe considered irregular, and the carpet or other article being patternedmay be deemed off-specification and unmarketable as first quality if theirregularity is sufficiently severe. It is also possible that individualapplicator characteristics, although within the envelope associated with“normal” applicator performance, may be sufficiently diverse as togenerate visually noticeable non-uniformities in “solid” or nominallyhomogeneous areas of the substrate pattern.

Irregularities of this type, while always undesirable, are particularlyvisually obtrusive in pattern areas which are intended to carry auniform solid color, as depicted by areas 70 and 80 in FIG. 2, becauseit is in these areas that the resulting bands, streaks, and (in the caseof momentary or intermittent malfunctions) non-periodic speckles orother pattern irregularities typically are the most visually prominent.

It has been unexpectedly discovered that an effective way to minimizethe prominence of such patterning artifacts is to develop a carefullyconstructed superpixel, comprised of individual pixels of the same ordifferent colors, for use as a repeating unit. By so doing, the visualimpact of one or more improperly functioning applicators can be soeffectively disguised so as to make the resulting pattern irregularitynearly invisible. There are several techniques that may be used toconstruct such superpixel, each of which shall be described below.

One preferred approach is depicted in FIGS. 3A through 3D. FIG. 3Adepicts a close-up view of a fill area in a pattern, showing the regulararrangement of pixels, each carrying one of the four different colorsthat collectively, in the pixel color ratios indicated, are necessary toform the target color for that fill area. As is shown in FIG. 3A, thepixels assigned lighter colors and the pixels assigned darker colors arearranged in separate columns (for example, columns 110 and 115,respectively). If the colorant applicator(s) responsible for theapplication of the respective colorants to columns 110 and 115 functionsimproperly, and the pixels in one such column are not colored asintended, the resulting pattern irregularity may quickly evolve into avisible pattern artifact due to the straight line nature of theirregularity, as well as the well-known propensity of the human eye todiscern such straight line “patterns” when viewed against themore-or-less uniformly colored background of the fill area.

FIG. 3B depicts an approach for adjusting the distribution of the pixelscomprising the fill area color in a way that minimizes the visual impactof an improper functioning colorant applicator under thesecircumstances. This approach begins with the construction of aMulti-pixel Offset Unit or M.O.U., as identified at 120 in FIG. 3B. Thisis simply a pixel array of the minimum size necessary to contain pixelshaving the proper colors—in relative numbers reflecting the proper colorratios—necessary to reproduce the target color in the fill area on thesubstrate. This may involve having some pixels with the same color (asindicated in FIG. 3B) or may involve a set of pixels in which each pixelhas been assigned a color that is unique within the M.O.U.

Where multiple pixels having the same color are used, it is preferredthat those pixels not be placed in side-wise adjacent relation (i.e.,same-color pixels should be separated, or, at a minimum, share only acommon corner, rather than a common side). For example, if the desiredcolor is a green, and the process colorants available include only blueand yellow, then the design of the M.O.U. should avoid, to the extentpossible, the occurrence of blue or yellow pixels in side-by-siderelationship. The visual effect of having groups of pixels assigned thesame color is somewhat mitigated by the quantity of colorant used, thedegree to which the colorant may be absorbed or diffused by thesubstrate surface, and other factors.

In the example depicted in FIG. 3A, it will be noted that the originaldesign shows rather prominent vertical banding due to the alignment ofpixels of similar colors in the vertical direction (i.e., colors arerestricted to specific columns). In order to reach the goal of havingall colors appear in each row, the M.O.U. depicted in FIG. 3B isconstructed, comprised of a single row eight columns in width. Withconsideration given to the specific arrangement of pixels within theM.O.U., the M.O.U. is then shifted one row down and three columns to theright, forming a “Z”-shaped superpixel 125 (the shape of which shall bereferred to an offset rectangular superpixel) indicated in FIG. 3C. Thisspecific offset yields a superpixel that, when tiled, creates columns ofpixels within the tiled areas in which, for every column, all pixelcolors are represented. Additionally, it will be observed that pixels ofthe same color are always separated (in a side-wise adjacent sense) byat least one pixel of a different color, although some pixels of thesame color are adjacent in a corner-to-corner sense.

In this way, when the superpixel 125 is tiled across a fill area of thesubstrate as indicated in FIG. 3D, that fill area will be perceived ashaving the desired color (i.e., the target color), and the variousconstituent colors contributed by individual pixels will be arranged ina way (i.e., in columns extending in the machine direction) that caneffectively mask the improper functioning of one or more colorantapplicators by preventing the formation of continuous streaks or bands(caused by a series of contiguous, improperly colored pixels extendingin the machine direction) on the substrate.

The array comprising the Multi-pixel Offset Unit can be square, butpreferably, as depicted in FIG. 3B, is more laterally oriented, i.e.,one having more columns than rows, where the columns are aligned withthe machine direction. This M.O.U. is then replicated and shifted, inboth the column direction (i.e., in the machine direction, or verticallyin the drawings) and row direction (i.e., laterally with respect to themachine direction, or horizontally in the drawings), for the purpose ofassuring that pixels of every assigned color will eventually appear ineach and every column. The number of columns and rows in the M.O.U.depends upon the number of different pixel color assignments necessaryto create the desired target color, as well as other factors. Althoughthe M.O.U. shown in FIG. 3B happens to be a 1×8 array, M.O.U.s (andcorresponding superpixels constructed from such M.O.U.s) are by no meansrestricted to single rows or to a minimum or maximum of eight columns.Indeed, it is contemplated that M.O.U.s and corresponding superpixelshaving a greater or lesser number of pixels, in rectangular, offsetrectangular, square, or other geometric configuration that accommodatesthe tiling of the superpixel.

M.O.U.s and corresponding superpixels of this kind may be generatedmanually, or perhaps with the assistance of a dithering algorithm, usingsoftware such as Adobe PhotoShop® published by Adobe SystemsIncorporated, San Jose, Calif., or other suitable design software. Insuch software, the original pattern is analyzed, on a pixel-by-pixelbasis, and an M.O.U.—preferably, but not necessarily, in the form of arectangular array—comprising all colors necessary to create the targetcolor is identified. As indicated in FIG. 3C, a geometric translation oroffset is then performed to arrive at a superpixel that, when tiled,has, in each column (perhaps as extended over multiple adjacentsuperpixels), pixels representing each of the different colors from theoriginal M.O.U.

While this approach is relatively simple to implement, and willeffectively reduce the visual impact of banding and streaking due tocolorant applicator malfunctions, it may be less effective at reducingthe occurrence of certain pattern artifacts that result from thegeometric alignment of individual elements within the pattern, as thoseelements are tiled throughout an area of the substrate. For illustrativepurposes only, it may be seen that the variously colored pixels depictedin FIG. 3A can generate a pattern artifact in the form of distinct“lines” 130 in a diagonal direction (sometimes referred to as twilllines) within the pattern area. In many cases, these twill lines aredesirable, or, if not, the combination of substrate absorbency, colorantquantity, and other factors is sufficient to diffuse and mask suchareas, thereby preventing the formation of visually obtrusive twilllines. However, in some cases, such twill lines can become visuallyobjectionable where, for example, the pattern is viewed at a relativelylow sight angle, as may occur if the pattern extends across a relativelylarge expanse of substrate (e.g., the carpeting of a large room).

In those situations in which the use of M.O.U.s in accordance with theteachings above results in the formation of twill lines that causevisually objectionable pattern artifacts, an alternative embodiment forthe arrangement of pixels within a superpixel may be used. Through useof this alternative embodiment, as described below, the resultingsuperpixel (1) will be relatively resistant to the formation ofpatterning irregularities due to the malfunction of one or more colorantapplicators, as discussed herein, and (2) will be relatively resistantto the formation of patterning artifacts such as twill lines.

It has been unexpectedly determined that adaptation of some of thetechniques used in the art of constructing sateen weaving patterns canbe advantageously adapted to the generation of superpixels, to achievethe same goals as the technique described above, i.e., distributingpixels within a superpixel in a manner that reduces the apparentalignment of pixels of the same or similar color, so that applicatormalfunctions do not generate bands and streaks that appear so visuallyprominent as to render the pattern visually objectionable. Inparticular, the techniques and patterns used to generate irregularsateen weaves have been found to be particularly well suited to thegeneration of superpixels that do not give rise to visually prominentpattern artifacts, including unintended twill lines. The details ofthese novel adaptations are given below.

FIG. 4 depicts a 4×4 array 140, representing 16 individual pixels, eachrepresenting one of four different colors, arranged within a 4×4superpixel. The relative numbers of the respectively colored pixels isdetermined by the desired target color within the fill area of thepattern, and may be adjusted as necessary. The arrangement of theindividually-colored pixels within the superpixel, however, ispreferably in accordance with the arrangement set forth in FIG. 4. Thisarrangement, derived from and analogous to irregular sateen patternsfound in the weaving art, involves the strategic placement of colors ina way that minimizes or prevents the occurrence of same color more thanonce in any given row or column, and minimizes the occurrence ofpatterning artifacts such as twill lines generated by the diagonalalignment of pixels of substantially the same color. At the same time,this arrangement achieves its primary objective, that of a superpixelconstruction that is resistant to patterning irregularities due to themalfunction of one or more colorant applicators, a consideration totallyinapplicable to the weaving art.

There are various ways in which the actual selection of color to beassigned to each of the 16 pixels can be made. For example, one can usea dithering algorithm to develop a spectrum of colors that, whenproperly arranged, will mimic the desired target color. Becausedithering algorithms usually define both the proportion and thearrangement of variously colored pixels on the substrate, using theteachings herein in combination with dithering techniques must be donewith care to avoid compromising the chromatic or visual effectiveness ofthe resulting dithered pattern. Accordingly, in many cases it will bepreferred to use the teachings herein in conjunction with moretraditional methods of superpixel generation, i.e., using the skills ofa designer to construct, on a pixel-by-pixel basis, a superpixel havingthe desired composition of variously colored pixels, distributed inaccordance with the teachings herein, to be used in coloring a givenfill area within an overall pattern.

Although a superpixel based upon the 4×4 array discussed above may bequite effective in emulating the desired target color, it imposes amoderate limitation on the designer in terms of the number of pixelsavailable to (1) generate the desired perceived color, through ditheringor other means, and (2) distribute the variously colored pixels withinthe superpixel in a way that minimizes both heather and the appearanceof twill lines. It has therefore been found preferable in many cases touse a somewhat larger array, thereby increasing the flexibility ofindividual pixel placement and the range of perceived color that can berepresented by the superpixel. If a primary objective of minimizing theinadvertent generation of visually prominent twill lines is to be met,the construction of larger N×N arrays should limit N to even integers;arrays of odd order (e.g., where N is an odd integer) tend to arrangesimilarly colored pixels in ways that form diagonal twill lines,analogous to the teachings associated with the theory of “regular”sateen weaving constructions.

FIG. 5 depicts a 6×6 array 150, representing 36 individual pixels withina 6×6 superpixel. As shown in FIG. 5, it has been assumed that a totalof six different colors will be needed to reproduce the desired targetcolor. As before, different proportions of the various colors may beused, as necessary. It should be noted that, once the placement of thefirst color within the superpixel is complete, the placement of theremaining five colors can be derived simply from choosing a procedure(e.g., consistently placing each successive color in the pixel havingsame relative position with respect to the preceding pixel, as explainedbelow) that will place those remaining colors in the same positionrelative to the first color. By so doing, the placement of the remainingcolors can be presumed to be placed in a way that will minimize orprevent the occurrence of pattern artifacts, and will also serve theoverall objective of creating a superpixel that is resistant to colorantapplicator malfunctions.

Accordingly, the superpixel depicted in FIG. 5 has been constructed byassignment of the first color in accordance with sateen weavingpractice. For purposes of discussion, such pixels may be referred to as“base” pixels, as these pixels form the reference points from which thecolor assignment of all other pixels within the superpixel aredetermined. The second color is assigned to the pixel directly above thefirst color pixel in each of the columns. The third color is assigned tothe pixel directly above the second color pixel in each of the columns,and so forth, with appropriate wrapping, i.e., with the assignmentreverting to the bottom of each column when the upper portion of thecolumn is filled. Alternatively, the procedure could have called forassignment of the second color to the pixel to the immediate right ofthe first color, assignment of the third color to the immediate right ofthe second color pixel, and so forth, with appropriate wrapping in eachcase.

By extension, corresponding assignments to the left, or below, or someother consistent relative placement using the pixel assigned to theimmediately preceding color as the “base” or reference pixel, is alsocontemplated. The objective of these various placement algorithms is thesame: by consistently following the same rule for all colors in thesuperpixel, the individual pixels of a given color will be distributedthroughout the area tiled by the superpixel in the same way as thepixels of all other colors contained in the superpixel (i.e., whenaccommodations are made for lapping, all pixels of any given color formthe same pattern within the area tiled by the superpixel).

This approach can be adapted to superpixels constructed from largerarrays, as well.

FIGS. 6A and 6B depict alternative 8×8 superpixels 160A and 160B, againwith placement of the base pixels carrying the first color being inaccordance with sateen weaving practice and using the “adjacent andabove” process to establish the position of the remaining seven colors.FIGS. 7 and 8 show respectively larger superpixel constructions for use,for example, where a larger number of individually colored pixels mustbe used as dither elements to generate the desired overall color fromthe available set of process colors.

Depending upon the choice of colors, it has been found that, while allsuch procedures might be equally effective at minimizing the generationof twill lines, not all are equally effective at distributing variouscolors throughout the superpixel in a way that maximizes the relativeuniformity or homogeneity of the color throughout the pixel. Forexample, if a dithering algorithm specified a given proportion ofindividual blue and green pixels within a superpixel in order to achievea desired overall color, it would be undesirable to consolidate all theblue and green pixels and place them on opposite sides of thesuperpixel, rather than intersperse them throughout the superpixel (tothe extent consistent with the dithering algorithm and the resultingoverall visual effect presented by the dithered area).

The preceding discussion has been primarily directed to the distributionof colors within a superpixel. The discussion that follows is directedprimarily to the selection of the colors to be distributed, with theobjective of emulating, as closely as possible given the selection ofavailable process colorants and available blending and ditheringtechniques, the target color in fill areas of the substrate.

If the number of process colors needed to generate a given pattern isrelatively small and a specific fill color area within that pattern isparticularly large or otherwise prominent (or, for example, if the“pattern” consists of a single uniform solid color that is a processcolor or a simple in situ blend of a relatively few process colors), itis contemplated that the patterning device can be operated with severalof the color bars dispensing the same colorant, but with use of thetechniques disclosed herein for distributing such colorant on thesubstrate surface. If, for example, the substrate is to be dyed auniform shade of red, and that color corresponds to an available processcolorant, then several of the color bars (e.g., bars 1 through 4, orbars 2, 4, 6, and 8) of the patterning device of FIGS. 1 and 2 can beloaded with that same red process colorant. The manner in which thiscolorant is applied to the substrate, however, is governed by theteachings herein—a superpixel is constructed in which the colorants fromcolor bars 1 through 4 are regarded as separate and distinct forpurposes of assigning colorant to individual pixels within the area ofthe substrate to be colored, and that superpixel (e.g., one constructedalong the lines of FIG. 3C or FIG. 4) is tiled across the surface of thesubstrate. The overriding principle is similar: relying upon differentcolorant applicators to provide the same colorant to different side-wiseadjacent pixels extending in the machine direction.

By so doing, the contribution of the colorant applicators on anyindividual color bar 1 through 4 is dispersed throughout the superpixeland thereby effectively dispersed throughout the pattern area in amanner that encourages an artifact-free, uniformly colored solid shadearea that is free of visually obtrusive bands and streaks due toapplicator malfunctions (or perhaps due merely to within-specificationmechanical differences among various colorant applicators). It should benoted that, where an artifact-free, uniformly-colored solid shade isdesired, it may be unnecessary to use a superpixel containing 16 or morepixels (as depicted in FIGS. 3C and FIGS. 4 through 8), particularly ifthe target color is expressed by a process colorant or can be easilyderived (e.g., via in situ blending) from a relatively few processcolorants. In that case, it is contemplated that smaller superpixels,perhaps containing as few as four pixels, may be used, either in asquare array, an offset rectangular array, or some other readilytile-able configuration. Specifically contemplated in such circumstancesare superpixels in the form of N×M pixel arrays, where N and M can beequal or different, and the total number of pixels can be 4, 6, 8, 9,10, 12, or 14.

At the other extreme, where the desired pattern requires colors that donot easily correspond to the process colors in use, but rather must bederived from a given set of process colors, several techniques may beused. For example, two or more colorants may be applied to the samepixel area, thereby forming an in situ blend of the two process colors.By adjusting the order and the relative proportion of the deliveredcolorants, an individual pixel can be made to carry any one of aspectrum of colors not directly represented by any single process color,but rather represented by various combinations of the process colors(i.e., various combinations of process colorants). A second exampleinvolves dithering, a well-known graphic arts technique in which a pixelof a given, unavailable color (i.e., not a process color or anachievable blend of process colors) may be approximated by thesubstitution of a small group of pixels that are colored with processcolors or achievable blends of process colors (collectively, such colorsare said to make up the “dither palette”) in a way that, at a distance,gives the appearance of the desired color.

There are many software algorithms available to accomplish dithering,such as those found in Adobe Photoshop®, Adobe Illustrator®, CorelDraw®, etc. or those based upon the work of Thiadmer Riemersma, asdescribed in “A Balanced Dithering Technique,” appearing in theDecember, 1998 issue of C/C++ User's Journal, or, often preferably,those based upon Floyd-Steinberg dithering and described, for example,in the article appearing at Page 253 of the Mar. 28, 1995 issue of in“PC Magazine.” The image to be dithered is analyzed and re-constructedusing only pixels having colors found in a predetermined ditheringpalette, using the conventional dithering techniques found in thecommercially available software discussed above, or other appropriatedithering software.

The colors that comprise the dithering palette may be those colorscomprising the “primary” or process colors available for dispensing bythe patterning system to be used, for example, the colors associatedwith each of the eight color bars 15 of FIGS. 1 and 2. If the printingsystem allows for the in situ blending of colors, in which differentcolors may be generated by the mixing or migration of colorants afterthe colorants have been applied to the substrate, the dithering palettemay be augmented by the addition of various combinations of processcolors, as applied to the same or adjacent pixels, thereby forming insitu mixtures or blends of process colors on the substrate surface. Thiswill provide a dithering palette having many more colors that the numberof available process colors. In a preferred embodiment, the colors ofthe dithering palette are comprised of (1) colors of the availableliquid colorants to be used in the printing process, (2) pre-selectedproportional blends of those colors, as those colors would appear ifapplied in sequence to the same pixel and allowed to mix on thesubstrate, one color superimposed on the other, to achieve an in situblend of the applied colors, and (3) colors in which such proportionalblends are intended to migrate and mix across pixel boundaries in acontrolled, predictable way, for example, in accordance with theteachings of commonly-assigned U.S. patent application Ser. No.08/834,795, the teachings of which are hereby incorporated by reference.

The above-referenced U.S. patent application describes a special case inwhich a potential limitation in the colorant delivery system may beovercome when attempting to generate mixtures of colors on a substrate.It is known that colors that are not available as process colors may begenerated by blending specific combinations of process colors on thesubstrate, i.e., two or more different colorants are applied to the samearea on the substrate and are allowed to mix, thereby forming a newcolor. A potential problem arises when the relative proportion of aconstituent colorant is less than the delivery system of the patterningdevice can accommodate.

For example, assume that a specific shade of green is desired, and mustbe generated from a combination of process colorants of blue and yellow.Assume further that the specific shade of green desired is achievableonly if the relative proportion of those colorants, individually appliedto the same pixel-sized area of the substrate, is 2 parts blue and 8parts yellow. The valve response of the patterning device may be unableto deliver the blue colorant in such a small quantity—assume, forexample, that a 30% saturating quantity (based on a baseline saturatingquantity of 100%, i.e., that quantity that is sufficient to fullysaturate, but not oversaturate, the substrate at that location) is thesmallest quantity of colorant that can be reliably delivered to anindividual pixel. In that case, it is possible to form the desired shadeof green by forming a multiple pixel structure, generally comprised ofbetween two and sixteen or more individual, contiguous pixels that maybe used within the image in the same manner as a single pixel. Thenumber of pixels to be used depends upon a number of factors, includingthe ratio of colorants forming the desired blended color and the desiredrelative granularity or “heather” that is artistically acceptable in thepattern.

This multiple pixel structure, a specific kind of superpixel referred toas a “metapixel,” is characterized by the formation, within themetapixel, of individual pixels that are relatively oversaturated withcolorant and adjacent pixels that are relatively undersaturated withcolorant, thereby encouraging the migration of colorant from theoversaturated areas to the undersaturated areas. As a consequence,minimum colorant delivery limitations can be overcome by calculating anddelivering a quantity of colorant that, on average, meets theproportional blending requirements of the desired color. In thisinstance, the blue and yellow colorants are applied to the group ofcontiguous pixels forming the metapixel in a way in which the averagequantity of blue colorant contained throughout the metapixel is 20% andthe average quantity of yellow colorant contained throughout themetapixel is 80%, yielding an average quantity of colorant that is 100%,i.e., that quantity of colorant that saturates, but does notoversaturate, the substrate at that location. As explained below, thiscan be achieved using several combinations or arrangements of pixels towhich various individual colorant quantities—but never less than 30% ofany single colorant—have been applied.

An elementary metapixel can be imagined by thinking of four contiguouspixels, arranged in a square (e.g., 2×2) array, intended to reproduce ashade of green. Assume that two of these pixels, perhaps arranged alonga diagonal, each contains 40% of a saturating application of bluecolorant, as well as 80% of a saturating application of yellow colorant.While each of these applications of colorant would be undersaturating ifconsidered individually (because each is less than 100%), thecombination of colorants in each of these two pixels results in a 120%level of saturation (40%+80%), and therefore results in an oversatuatingcondition within those two pixels. Assume that into the remaining twopixels comprising the square array is placed an 80% saturatingapplication of yellow colorant. The resulting combination averages to a20%/80% proportion of blue colorant to yellow colorant within the fourpixel array, which presumably is the appropriate ratio needed toreproduce the desired shade of green, and yields an average saturationlevel of 100%. Given the absorbent nature of the textile substrates towhich this technique is applicable (which substrates tend to promoteinter-pixel blending of colorants, and, particularly, the migration andblending of colorants from oversaturated areas into undersaturatedareas), the overall effect is that of a four pixel array in which theoverall color is similar to that which would have been obtained by theapplication of a 20% quantity of blue colorant and an 80% quantity ofyellow colorant to each of the four pixels comprising the array.

Alternatively, this same overall colorant average within the metapixelarray could have been achieved by the same 40% application of bluecolorant to the same two pixels within the array, but with the remainingtwo pixels each receiving all of the necessary yellow colorant (i.e., anoversaturating, 160% application). Generally, because this latterdistribution of colorants must rely more heavily upon unrestrictedcolorant migration on the substrate, the first described colorantapplication process (i.e., creating two individual pixels having a40%/80% blue/yellow colorant application and two individual pixelshaving an 80% yellow colorant application, and therefore constructing anarray in which the yellow colorant is more uniformly applied within thearray) will be preferred under most conditions. Of course, metapixelarrays comprised of other configurations of oversaturated andundersaturated pixels can be constructed—for example, 3×3 arrays, orirregularly shaped arrangements of pixels—so long as (1) the averageproportion of colorants within the metapixel array reflects theproportions of colorants desired, (2) overall average saturation levelwithin the metapixel does not appreciably exceed 100% (to avoid dryingand other problems), and (3) the minimum colorant delivery limitationsof the patterning device are observed.

The techniques described above are believed to be applicable to avariety of substrates, although absorbent textile substrates arepreferred. It is contemplated that such preferred substrates maycomprise interior fabrics and substrates, such as drapery and upholsteryfabrics, table linen, and various floor coverings, as well as othertextile applications (e.g., automotive interior fabrics and carpeting,automotive and non-automotive floor mats, etc.). It has been found thatthis technique is particularly well adapted for use in decorative floorcovering applications, including carpets, rugs, carpet tiles, mats, andthe like. The following are examples of two such applications.

EXAMPLE 1

The substrate is a high twist frieze cut pile carpet, comprised oftwo-ply, high twist nylon 6,6 yarn (1180 filament, 17 dpf) woven into a4 oz. woven polypropylene backing at 7.8 stitches per inch and having atufting gauge of ⅛ inch that results in a total finished pile height ofabout ¾ inch and a yarn weight of about 38 oz./sq. yd. This substrate isthen patterned in accordance with the teachings herein, as follows.

The pattern desired is merely a relatively uniform color, with theintentional introduction of heather for visual interest. The originalpixel-wise components of the desired color are indicated in FIG. 3A.However, because of the concentration of certain colors within certaincolumns, it is recognized that this pattern is vulnerable to streakingand banding. Accordingly, the same pixels, in the same proportion, arerearranged to form an M.O.U., as indicated in FIG. 3B. The M.O.U. isthen configured to form a superpixel that (1) represents the desiredcolor (due to the selection of the colors of the individual constituentpixels) and (2) forms a replicatable unit that can be tiled across thesubstrate, as shown in FIGS. 3C and 3D. The proper color applicatoractuation instructions are generated, and the carpet is patterned usingthe device of FIGS. 1 and 2. The result is a carpet having a pattern inwhich fill areas have an exceptionally uniform appearance and, at amodest viewing distance, give the appearance of a solid color, asdepicted in FIG. 9.

EXAMPLE 2

The substrate is a loop pile carpet tile, comprised of three-ply, spacedyed and heat set nylon 6,6 yarn tufted in ⅛ inch gauge resulting in afinished pile height of 0.125 inch and a yarn weight of 20 oz/sq. yd.The carpet backing is PVC-Free Comfort Plus Cushion. To give additionalvisual interest, the pile is sculpted somewhat, yielding a slightlyundulating surface. This substrate is then patterned in accordance withthe teachings herein, as follows.

The pattern desired is comprised of pre space dyed yarn that is thenoverdyed completely with areas of contrasting color, similar to thedesign shown in FIG. 10. The pixel-wise components of the desired colorfor the fill areas are determined by a designer using design software,and are determined to require six process colors. The arrangement ofthose colors, on an individual pixel basis, is accomplished inaccordance with the teachings herein, as indicated in FIG. 6A. Theresulting superpixel (1) represents the desired color (due to theselection of the colors of the individual constituent pixels) and (2)forms a replicatable unit that can be tiled across the substrate, asshown in FIG. 6A. The proper color applicator actuation instructions aregenerated, and the carpet is patterned using the device of FIGS. 1 and2. The result is a carpet having a pattern in which fill areas have anexceptionally uniform appearance and, at a modest viewing distance, givethe appearance of a solid color, as depicted in FIG. 10.

EXAMPLE 3

The substrate is a loop pile carpet tile, comprised of two-ply, hightwist nylon 6,6 yarn (1180 filament, 17 dpf) woven into a 4 oz. wovenpolypropylene backing at 7.8 stitches per inch and having a tuftinggauge of 1/10 inch that results in a total finished pile height of about¾ inch and a yarn weight of about 18 oz./sq. yd. To give additionalvisual interest, the pile is sculpted somewhat, yielding a slightlyundulating surface. This substrate is then patterned in accordance withthe teachings herein, as follows.

The pattern desired is comprised of a colored background with large fillareas of a contrasting color, similar to the design shown in FIG. 10.The pixel-wise components of the desired color for the fill areas aredetermined by a designer using design software, and are determined torequire six process colors. The arrangement of those colors, on anindividual pixel basis, is accomplished in accordance with the teachingsherein, as indicated in FIG. 6A. The resulting superpixel (1) representsthe desired color (due to the selection of the colors of the individualconstituent pixels) and (2) forms a replicatable unit that can be tiledacross the substrate, as shown in FIG. 6A. The proper color applicatoractuation instructions are generated, and the carpet is patterned usingthe device of FIGS. 1 and 2. The result is a carpet having a pattern inwhich fill areas have an exceptionally uniform appearance and, at amodest viewing distance, give the appearance of a solid color, asdepicted in FIG. 10.

EXAMPLE 4

Frieze

The specifications for one preferred form of a broadloom carpet productis described in the table below:

Frieze Broadloom Carpet

Preferred Embodiment (A) (B)  1. Product Name: Milliken ® PatternMates ™ carpet  2. Face: High Twist Frieze Cut pile  3. Primary Backing:Woven polypropylene (PolyBac - 4 oz/yd²)  4. Total Finished 38 oz/yd²Yarn Weight:  5. Stitches Per Inch: 7.81  6. Tufting Gauge: ⅛  7. YarnPolymer: Nylon 6,6  8. Yarn Type: 1180 filament, with antistat, semidull trilobal, 17 dpf  9. Yarn Twist: 7.50 twist per inch in singles (S)and ply (Z) 10. Yarn Ply: 2 ply twisted 11. Heatset: Yes, @ 260 to 264°F. with steam frieze 12. Yarn Size: 3.69/2 cotton count 13. Tufted PileHeight: 48/64 inches (¾″) 14. Dyeing Method Jet Dye, Millitron ® jet dyemachine 15. Precoat Adhesive Styrene Butadiene Latex, 12 oz/yd² coatingweight 16. Preferred Color Beige

EXAMPLE 5

Heavy Weight Frieze

The specifications for one preferred form of a broadloom carpet productis described in the table below:

Frieze Broadloom Carpet

Preferred Embodiment (A) (B)  1. Product Name: Milliken ® PatternMates ™ Pluscarpet  2. Face: High Twist Frieze Cut pile  3. PrimaryBacking: Woven polypropylene (PolyBac - 4 oz/yd²)  4. Total Finished 55oz/yd² Yarn Weight:  5. Stitches Per Inch: 11.75  6. Tufting Gauge: ⅛ 7. Yarn Polymer: Nylon 6,6  8. Yarn Type: 1180 filament, with antistat,semi dull trilobal, 17 dpf  9. Yarn Twist: 7.50 twist per inch insingles (S) and ply (Z) 10. Yarn Ply: 2 ply twisted 11. Heatset: Yes, @260 to 264° F. with steam frieze 12. Yarn Size: 3.69/2 cotton count 13.Tufted Pile Height: 48/64 inches (¾″) 14. Dyeing Method Jet Dye,Millitron ® jet dye machine 15. Precoat Adhesive Styrene ButadieneLatex, 12 oz/yd² coating weight 16. Preferred Color Beige

FIGS. 11A and 11B each show exemplary textile substrates orconstructions such as textile floor covering, such as cut or loop piletufted broadloom carpet (including tufting yarn, a primary backing, anda tuftlock or precoat such as latex with or without additional backingmaterials or layers such as a secondary backing, cushion or pad) havingon its face an arrangement of 16 different color areas or blocks ofsolid or heathered colors or shades. In FIG. 11A, each of the colors isseparated by, for example, black (or dark) dividing lines or borders. InFIG. 11B, the color areas or blocks are contiguous and not separated bydividing lines.

The color areas or blocks of FIGS. 11A and 11B may be produced by, forexample, printing, dyeing or graphics tufting the selected colors. It ispreferred that the color areas (and dividers or borders) be produced ona single substrate by printing or dyeing, and most preferred by jetdyeing by, for example, a Millitron® jet dye machine.

The textile substrate may be a large display carpet or rug, a smalldisplay sample rug, broadloom carpet, an area rug, floor mat, runner,carpet tile, or the like.

Preferably, the color areas are each distinct different solid colors orheathers or different shades of the same color or hue. The colors may berelated as being in the same color family or may be complimentarycolors. It is preferred that the colors be jet dyed as describe above ina fashion which eliminates, reduces, or masks streaks, bands,inoperative jets, or the like.

Alternatively, as shown in each of FIGS. 12A and 12B, exemplary textilesubstrates or constructions such as textile floor covering, such as cutor loop pile broadloom carpet have 16 different pattern areas or blockson the face thereof. In FIG. 12A, the pattern areas are separated, forexample, by black or dark borders or dividing lines. In FIG. 12B, thepattern areas are not separated by such borders or dividers.

Again the patterned substrates of FIGS. 12A and 12B may be formed by,for example, printing, dyeing or graphics tufting, but are preferablyformed by printing or dyeing, more preferably by jet dyeing, forexample, by a Millitron® jet dye machine.

FIG. 13 schematically represents a textile substrate, such as that ofFIG. 11A, having different shades of the color or hue red thereon. Forexample, 4 different light reds (LR1, LR2, LR3, LR4), 4 different mediumreds (MR1, MR2, MR3, MR4), 4 different reds (R1, R2, R3, R4), and 4different dark reds (DR1, DR2, DR3, DR4). For example, light red 1 (LR1)may be brighter than light red 4 (LR4). Such a color family, colorpalette, or color shade display carpet, rug, mat or tile as shown inFIG. 13 may or may not include dividers or borders between the colorareas (blocks) and may be sized for the desired purpose (large for afloor or wall, small for a sample in a sample rack or to be carried,shipped or mailed).

FIG. 14 shows a similar textile substrate having patterned areas orblocks of a similar pattern and different background colors or shades ofcolors. Each of the 16 areas or blocks has a similar pattern and adifferent background color or shade such as different colors or shadesof green (GR1, GR2, GR3, GR4), of blue (B1, B2, B3, B4), of yellow (Y1,Y2, Y3, Y4), and of red (R1, R2, R3, R4).

FIG. 15 shows a patterned textile substrate like that of FIGS. 12 and 13in that the 16 different areas or blocks have different patterns anddifferent shade of a color. As shown, the backgrounds are differentcolors, hues, or shades of blue (different shades of light blue (LB1,LB2, LB3, LB4), medium blue (MB1, MB2, MB3, MB4), blue (B1, B2, B3, B4),and dark blue (DB1, DB2, DB3, DB4). The different shades may be greyer,whiter, brighter, subdued, greener, yellower, etc.

The patterned textile substrate of FIG. 16 is like that of FIG. 14 inthat it has the same pattern in each of the pattern areas or blocks, butthe background colors are all the same and the pattern (or patternelement) colors are each different. As shown, the backgrounds orbackground color are all brown (BR1), while the patterns (or patternelements) are each a different color or shade (green (G1, G2, G3, G4),brown (BR2, BR3, BR4, BR5), white (W1, W2, W3, W4), blue (BL1, BL2, BL3,BL4)).

The textile substrate of FIG. 17 differs from that of FIGS. 11A-16, 18and 19 in that the base has sections (multiple areas or blocks) ofdifferent base constructions. As shown, there are cut, loop, and cut andloop (cut/loop) pile sections. Each section has 4 different areas orblocks of different colors, hues, or shades of red (R1, R2, R3, R4).

FIG. 18 shows a textile substrate like that of FIG. 13 except that eachof the color areas or blocks of FIG. 18 includes a color and/or shadecode, designation, or the like which helps identify the selected ordesired color and facilitates ordering product in that color. The colorand/or shade code may also designate a particular base, pattern, color,etc. In FIG. 18, the respective codes RD503, RD505, RD504, RD506 are forrespective different red shades (RD1, RD2, RD3, RD4). The textilesubstrate may or may not have dividers or borders between the color areaor blocks. Preferably, the color and/or shade code is printed or dyedright on the base along with the color, shade, pattern, or the like.

The textile substrate of FIG. 19 is similar to that of FIG. 18, exceptthat the color codes are located in white (or light colored, like lightbeige) boxes within the color or pattern areas or blocks. In FIG. 19,the codes X421, K777, Y972, B623 correspond to respective colors red(R1), blue (B1), green (G1), and yellow (Y1). Such color or shade codesmay be added to each of the color or shade or pattern areas or blocks ofthe textile substrates of FIGS. 11A-17.

Although the textile substrates of FIGS. 11A-16 have 16 color, shade orpattern areas, of FIG. 17 has 12, and of FIGS. 18 and 19 have 4, it isto be understood that the textile substrates of the present inventionmay have one or more such areas, preferably two or more, most preferablyfour or more. The more color areas per carpet, rug, mat, or tile, themore choices that are presented to a potential customer. Also, thedisplay or sample rugs may be of any desired size, shape (square,rectangular, oval, round, triangular, or the like), of any baseconstruction and the color or pattern areas thereon may be contiguous ornon-contiguous and may be of any size and shape.

In accordance with at least one embodiment of the present invention, aresidential broadloom (wall-to-wall) carpet product having heathered orsolid colors or color areas dyed or printed thereon using theabove-described super pixel constructions or patterning structures isprovided.

In accordance with at least one other embodiment of the presentinvention, a residential broadloom (wall-to-wall) carpet product havingone or more heathered colors or color areas dyed or printed thereonusing the above-described super pixel constructions or patternstructures is provided. Preferably, the heathered colors or color areasare produced using two or more colors or shades, more preferably threeor more colors or shades.

In accordance with at least one embodiment of the present inventionthere is provided a coordinating multi-colored twist yarn carpet havingspecial applicability as a display carpet and selling tool and whichincludes the colors in a colorline of a product being displayed on onepiece of carpet or a display rug. The number of colors included can bemore than two with no limit to the maximum number. All of the includedcolors are designed on or in a quilt type or patchwork type fashion. Theindividual color areas can be printed or dyed on one substrate ormanually seamed together. The display carpet or rug is for the purposeof showing the colors available in a product line to aid in themerchandising of that product. The display carpet or rug may bedisplayed on the floor, on the wall, or the like.

For example, FIG. 20 shows an example of such a display carpet or rughaving over 100 different colors (solids or heathers) in the form ofrectangular color areas set out in a rectangular array on a carpet orrug having dimensions of about 4′×21′ with each color area havingdimensions of about 9.6″×1′. Each of the colors is preferably a heatherpattern or structure of three or more colors (process colors, blendedcolors, or target colors). One example of such a display carpet or rugis a Pattern Mates™ display rug showing, for example, 105 differentPattern Mates™ heathered colors produced on a single textile substrateby a Millitron® jet dye machine by Milliken & Company of LaGrange, Ga.

Such a display carpet or rug may be used alone or in combination withadditional selling tools such as individual samples of multiple colorsor color shades to show the product. The size of the samples arepreferably 27″×18″, which is a standard sample size in the carpetindustry, but not limited to this size. The sample carpet, rug, runneror blanket for these individual samples will preferably have more thanone color or color shade in a rectangular array or other format acrossthe sample or in the width of the sample. For example, FIGS. 11B, 13,18, and 19 show color display rugs or samples having multiple colors,coordinating colors, contrasting colors, and/or shades of one color orhue. This gives the ability to show a lot of color in just a fewsamples. The problem has always been too many samples. This will relievethe need for many samples. For example, if each sample carpet or rugshows 6 colors from individual color families, then with 20 samples youwill show a total of 120 colors instead of only 20 . The patchwork typeformat can be used for both large floor or wall sample rugs and smallerindividual sample rugs.

Production of these color sample rugs or carpets is facilitated by theability to dye multiple and different colors in squares or any shapes onone individual textile base or continuous textile base. This includes,but is not limited to dyeing or printing on broadloom carpeting of anywidth, area rugs, mats, accent rugs, runners, and carpet tiles of anysize and shape. Colors can be organized in any scheme from families incolor palettes, coordinating colors, to collections of unrelated colorsin any shape or size.

For example, a large display rug having 20 major colors or hues thereonmay be used along with 20 different smaller sample rugs each having 4different shades of one respective major color or hue thereon. The largedisplay and small sample rugs may be tufted, bonded, woven, knitted,non-woven, or the like and may have a non-skid or cushion backingthereon. Further, the face may be carved, sculpted, cut pile, loop pile,textured, and/or the like. The large display rug and smaller sample rugsmay form a marketing system and may be formed by printing or dyeingbroadloom carpet, and then cutting out the large and small rugs. Therugs may be cut out by hand, die cut, ultrasonic cut, laser cut, waterjet cut, scissor cut, blade cut, hot knife cut, in-line saw cut, rotaryknife cut, machine cut, or the like. The cut rugs may also be edgetreated, edge trimmed, sheared, fringed, surged, capped, sewn, binded,sealed, seared, edged, matted, beveled, or the like. The products beingdisplayed may be broadloom carpet, carpet tiles, mats, rugs, runners,area rugs, wall covering, surface covering, or the like for theresidential, commercial, industrial, institutional, or hospitalitymarkets. Such display rugs, color family rugs, patterned rugs, colorarea rugs, and/or the like facilitate and enhance the purchasingexperience as well as provide the potential customer with more choicesin color, pattern, design, shade, base construction, and/or the like.Hence, numerous floor covering or surface covering products or productlines may be displayed, marketed, merchandized, or sold in this manner.

Process A

-   1. Customer and/or Dealer submits Color Sample to Supplier and/or    Dealer or Website.-   2. Dealer and/or Supplier analyzes color sample and determines best    matching and/or coordinating colors.-   3. Supplier manufactures Color Selection Blanket, Color Family    Blanket, and/or Product Samples and direct ships to Customer and/or    Dealer.-   4. Dealer and/or Supplier provides electronic, paper copy and/or    textile Color Blanket and/or Color Family Blanket and/or Product    Sample to Customer.-   5. Customer and/or Dealer orders products, samples and/or additional    Color Selection Blankets, and/or Color Family Blankets.-   6. Customer and/or Dealer orders Products and/or Product Samples.-   7. Customer and/or Dealer orders Products.-   8. Products and/or Product Samples manufactured by Supplier and    direct shipped to Customer and/or Dealer.

Process B

-   1. Customer goes on-line, to Dealer, and/or to Retailer and looks at    Product Samples, Products, Color Selection Blankets, and/or Color    Family Blankets.-   2. Customer, Dealer and/or Retailer downloads or prints out Samples,    Color Selection Blanket, and/or Color Family Blanket.-   3. Customer takes Sample, Color Selection Blanket, and/or Color    Family Blanket home.-   4. Customer, Dealer and/or Retailer orders one or more Products,    Product Samples, Color Selection Blankets, and/or Color Family    Blankets from Dealer, Retailer and/or Supplier.-   5. Supplier manufactures Products, Product Samples, Color Selection    Blankets, and/or Color Family Blankets and direct ships to Customer,    Dealer and/or Retailer.-   6. Customer takes Sample, Color Selection Blanket, and/or Color    Family Blanket home.-   7. Customer, Dealer and/or Retailer orders one or more Products,    Samples, Color Selection Blankets, and/or Color Family Blankets from    Dealer, Retailer and/or Supplier.-   8. Customer, Dealer and/or Retailer orders Products and/or Samples.-   9. Customer orders Products and/or Product Samples from Dealer,    Retailer and/or Suppler.-   10. Customer orders Products from Dealer, Retailer and/or Supplier.-   11. Products and/or Product Samples manufactured and direct shipped    to Customer, Dealer and/or Retailer.

FIG. 20 shows a large color selection (product line) display carpet,rug, blanket or the like. Such a carpet or rug can be used as any othercarpet or rug. Preferably, such a carpet or rug is used to advertise,market or display the available colors or patterns in a particularproduct line, such as residential, commercial, institutional, orhospitality broadloom carpet.

In accordance with a particular example and as shown in FIG. 20, thedisplay carpet or rug has over 100 different colors (heathers) jet dyedon a high twist yarn cut pile (frieze) broadloom carpet base (38 oz./yd²face weight).

FIGS. 21-23 show how a particular heather patterned carpet product cancoordinate or match with one or more other flooring products. A heatherpattern with two or more colors or shades is preferred and with three ormore colors or shades is more preferred. FIGS. 21 and 22 show differentpieces of ceramic tile coordinating with a multi-colored cut pilecarpet. FIG. 23 shows ceramic tile and a laminate or vinyl tilecoordinating with a multi-colored cut pile carpet.

FIG. 24 shows a large piece of pattern carpet coordinating with severalselections of different multi-colored (heather patterned) cut pilecarpet pieces or samples (blue, red, rose, etc.).

FIG. 25 shows different ceramic, vinyl or laminate tile piecescoordinating with several different multi-colored (heather patterned)carpet samples or pieces.

FIG. 26 shows a vinyl or laminate self-stick tile coordinating withseveral multi-colored (heathered) carpet samples.

FIG. 27 shows two ceramic tiles coordinating with several differentmulti-colored (heathered) carpet samples or pieces.

It has been discovered that a multi-colored twist yarn carpet can becoordinated with pattern carpet, carpet tiles, ceramic tiles, laminate,vinyl, other flooring, room decor, furnishings, drapery, and the like.The heather or multi-colors of a twist yarn carpet can be coordinatedwith the colors of pattern carpet. The twist yarn carpet substrate canbe all white (undyed), precolored, postcolored, or spaced dyed with anoverflow applicator and then printed or dyed to provide the multi-colorpattern or heather. The multi-colored carpet can be tufted, woven, handgunned, hand made, or the like. Preferably, the multi-colored twist yarncarpet has up to three or more colors of metapixel blending per singleend of fiber to give very different colors. The high turn twist carpetis preferably finished in 6′, 12′ or 13′6″ wide carpets. The multi-colortwist carpet color coordinates with pattern carpets, ceramic tile,laminate, and/or vinyl made up of various designs, figurative,contemporary, eclectic, geometric, or any other of such designs.Examples of such designs include floral, ornamental, speckled, heathers,and subtle. For example, the color coordination is between a patterncarpet, ceramic tile, laminate, and/or vinyl being installed in one roomor area of a house and the multi-colored twist carpet being installed inanother. Thus, complementing the interior design of the rooms.

With reference to FIGS. 11A, 11B, 36, and 37 of the drawings, a displaysystem as shown in FIG. 37 is made up of a display rug (such as shown ineither FIG. 11A or 11B) and a display cover shown in FIG. 36. Thedisplay system of FIG. 37 is preferably presented in a vertical or nearvertical orientation and labels or identifying information is providedadjacent each different color area to provide the customer, potentialcustomer, system user with ready access to the information needed toselect and order the desired color, pattern, base, or the like. Therespective identifying information is preferably included in each of theelongated rectangular boxes above each of the color area windows.

If desired, the display cover may be hinged to provide access to theunderlying display rug to, for example, allow the rug to be changed out,to be viewed uncovered, to be taken near a window to see it in sun lightor the like.

It is preferred that the transparent material of the display cover be asolid sheet of transparent plastic, acrylic, Lucite, plexiglass, glassor the like. The frame or borders of the display cover may be separatefrom or attached to the transparent sheet. It is preferred that theborders or frames of the display cover be over top of the transparentsheet.

The display system of the present invention may display one or morecolors, patterns, bases, or the like, preferably two or more, morepreferably 4 or more and may be any size or shape.

With reference to FIG. 38, the display rug may include non-contiguouscolor or pattern areas separated by, for example, a white or lightbackground (such as off white, light beige, or the like). Also, thecolor or pattern areas may be of any shape such as circular.

With reference to FIG. 39, the display rug may include contiguous bands,strips, or the like of different colors or patterns across its width (ordown its length or at any angle across its face).

With reference to FIGS. 40-42, a display system includes a plurality ofcolor family or color palette display rugs or articles, each having aplurality of color (or shades) areas thereon, and can be used to marketsolid or heather colored broadloom carpet and to allow a customer oruser to coordinate or match the carpet to other flooring, wall covering,furnishings, pattern carpet, or the like.

In accordance with one particular residential broadloom carpet example,a total of 270 different colors are displayed on 18 different colorfamily samples or rugs each having 15 different colors thereon. Also,the customer, dealer, retailer, or potential customer can select fromdifferent bases (for example, three or more different bases, such as cutpile, loop pile, textured, and/or the like). For example, they may beable to choose from five different carpet constructions or bases, suchas, 32 oz. (yarn face weight) textured Saxony, 40 oz. straight setSaxony, 38 oz. frieze, 55 oz. frieze, or 42 oz. textured loop. Forexample, residential broadloom carpet sold by Milliken & Company ofLaGrange, Ga., under the tradenames Bastion, Lamprey, Concord, Verde,and Assabet. This gives the customer at least 1,350 different choices(base and color) in a residential broadloom carpet. By adding frames,borders, inlays, or the like, there are over 2,000 choices orcombinations.

If a customer or potential customer is unsure of a particular choice ofbase and color, they may order a sample of the particular color and base(for example, a 9 inch square or 18 inch square piece of carpet, an 18inch×24 inch rectangle, or the like) or they may order a color familysample or rug of the selected base and having the selected color alongwith related or coordinating colors (for example, the selected color and14 other related colors (color family) on the selected base in an 18inch×24 inch sample).

In accordance with one particular example of the present invention, eachcolor family sample rug for display purposes at a store, dealer,retailer, or the like such as Carpet One, Home Depot, Lowe's, or thelike, has 15 different colors, patterns, designs, or shades thereon, isabout 24 inches wide×40 inches long, with each of the 15 differentcolors or the like defining an about 8 inch×8 inch square area, witheach of the 15 color areas being contiguous, the base being, forexample, one of cut and/or loop pile tufted, bonded, woven, knitted,flocked, or the like, and with the color, pattern, designs, textures, orshades preferably being produced in broadloom form by one of dyeing,printing, tufting, weaving, painting, and/or the like, most preferablydyeing or printing and even more preferably jet dyeing.

In accordance with another particular example, 240 total differentcarpet colors are displayed on 2 color family or color selection samplesor rugs, each having 120 different colors thereon in relatively smallcontiguous rectangular areas. Also, each color is available on one ormore bases, for example, one of 5 different bases, such as, 32 oz. (faceyarn weight) textured Saxony, 40 oz. straight set Saxony, 38 oz. frieze,55 oz. frieze, or 42 oz. textured loop. This provides the customer orpotential customer with 1,200 different choices (base and color).

In accordance with a preferred embodiment, customers, dealers,retailers, stores, distributors, or the like can order color samples,color family samples, color family rugs, carpet tiles, rugs, carpets,runners, broadloom, and/or the like with no minimum order and directshipment in either 24 hours, 3 days or 7 days from placing the order(depending on the base, color, pattern, texture, finish, inventory,special order, or the like). In accordance with the preferredembodiment, the customer either takes the desired product (base andcolor, color sample, color family sample, and/or the like) frominventory or makes an order (special or custom order) for the desiredsample or product. It is preferred that the product or sample beproduced on demand (when ordered) to eliminate or at least reduceinventory, can be printed, dyed, tufted, or the like in broadloom form,cut to shape, size or length, and then direct shipped to the customer,store, etc.

It should be understood that the specifics of the construction of thetextile substrates in the above examples are not critical. Thepatterning techniques disclosed herein are applicable to a variety ofabsorbent textile substrates, including, but not limited to, carpets,carpet tiles, rugs, and mats having the widest variety of constructions,so long as each has sufficient dimensional stability for acceptabletransport and pattern transfer and the face yarns are capable ofaccepting dye in an acceptable manner.

While the invention has been described in connection with theembodiments discussed above, it is not intended to limit the scope ofthe invention to the particular form set forth, but on the contrary, itis intended to cover such alternatives, modifications, and equivalentsas may be included within the spirit and scope of the invention asdefined by the appended claims.

1. A textile substrate for coordinating with other flooring,furnishings, pattern goods, or the like, having one or more patterns,colors or shades thereon produced by a process including the steps ofconstructing a superpixel to be replicated on the surface of thesubstrate, said superpixel being comprised of a plurality of contiguouspixels that collectively provide said superpixel with a geometric shapethat can be tiled on said substrate surface, each of said plurality ofcontiguous pixels comprising said superpixel being assigned a color froma dither palette in a relative proportion to simulate a target color,wherein at least two different colors are individually assigned withinsaid superpixel in accordance with a placement algorithm that precludesthe assignment of the same color on adjacent pixels within saidsuperpixel, and applying said colors to the surface of the substrate bytiling said superpixel in a repeating manner across the surface of thesubstrate such that on the surface of the substrate no adjacent pixelshave the same color, wherein said substrate is one of a display orsample carpet or rug, and comprising a plurality of shades, colors orpatterns of a color or product line on a single carpet or rug substratefor display as a selling tool.
 2. The substrate of claim 1, wherein theplurality of shades, colors or patterns of the substrate are adapted tocoordinate with at least one of pattern carpet, carpet tiles, ceramictiles, laminate, vinyl, other flooring, room decor, furnishings,drapery, or combinations thereof.
 3. The substrate of claim 1, whereinthe plurality of shades, colors, or patterns of the substrate areadapted to coordinate with at least one of ceramic, laminate, and vinyltiles.
 4. The substrate of claim 1, further comprising a plurality ofcolor or pattern codes or designations on the substrate.
 5. Thesubstrate of claim 1, wherein each of the plurality of shades, colors orpatterns of the substrate has its own unique color or pattern code ordesignation.
 6. The substrate of claim 1, wherein at least 3 differentcolors or shades make up each of the plurality of shades, colors orpatterns.
 7. The substrate of claim 1, wherein the substrate representsbroadloom carpet which coordinates with other flooring.
 8. A displaysubstrate having at least four areas of different patterns, colors orshades produced by a process including the steps of constructing asuperpixel to be replicated on the surface of the substrate, saidsuperpixel being comprised of an N ×N array of pixels, each of saidpixels having been assigned a color from a dither palette in a relativeproportion to simulate a target color, wherein said colors are assignedwithin said superpixel in accordance with a placement algorithm thatassigns a given color to a pixel in each of the N rows and each of the Ncolumns in a manner that said given color is found no more than once inany row or column in said array and each pixel assigned to said givencolor is surrounded by pixels to which other colors have been assigned;and applying said target color to the surface of the substrate byapplying said superpixel in a repeating arrangement across the surfaceof the substrate such that on the surface of the substrate said givencolor is present no more than once in any row or column in saidsuperpixel and on the surface of the substrate each pixel assigned tosaid given color is surrounded by pixels to which other colors have beenassigned, wherein said substrate includes at least 4 of said areas ofdifferent patterns, colors, or shades, and wherein said substrate is oneof a display or sample rug or carpet, and comprising a plurality ofshades, colors or patterns of a color or product line on a single carpetor rug substrate for display as a selling tool.
 9. The substrate ofclaim 8, where N is at least
 4. 10. A display substrate having at leasttwo areas of different patterns, colors or shades produced by a processincluding the steps of constructing a superpixel to be replicated on thesurface of the substrate, said superpixel being comprised of an N ×Narray of pixels, each of said pixels having been assigned a color from adither palette in a relative proportion to simulate a target color,wherein said colors are assigned within said superpixel in accordancewith a placement algorithm that assigns a given color to a pixel in eachof the N rows and each of the N columns in a manner that said givencolor is found no more than once in any row or column in said array andeach pixel assigned to said given color is surrounded by pixels to whichother colors have been assigned: and applying said target color to thesurface of the substrate by applying said superpixel in a repeatingarrangement across the surface of the substrate such that on the surfaceof the substrate said given color is present no more than once in anyrow or column in said superpixel and on the surface of the substrateeach pixel assigned to said given color is surrounded by pixels to whichother colors have been assigned, wherein said substrate includes atleast two of said areas of different patterns, colors, or shades,wherein said substrate forms part of a display system, and comprising aplurality of shades, colors or patterns of a color or product line on asingle carpet or rug substrate for display as a selling tool.
 11. Thesubstrate of claim 10, wherein each of said areas of different patterns,colors, or shades is contiguous.
 12. The substrate of claim 11, whereinsaid substrate is a high twist, jet dyed cut pile carpet.
 13. Thesubstrate of claim 10, wherein N is at least 4.